U.S. patent application number 10/352948 was filed with the patent office on 2003-08-07 for monitoring of critical dairy farm conditions.
Invention is credited to Bosman, Jack B., Stevens, Hilco, Stevens, John A., Wood, Larry J..
Application Number | 20030146834 10/352948 |
Document ID | / |
Family ID | 27663060 |
Filed Date | 2003-08-07 |
United States Patent
Application |
20030146834 |
Kind Code |
A1 |
Stevens, Hilco ; et
al. |
August 7, 2003 |
Monitoring of critical dairy farm conditions
Abstract
A system is provided herein for monitoring the quality of milk
which is stored at a dairy facility comprising sensors, e.g.,
analog and/or digital sensors that are installed on equipment on a
dairy farm. Such sensors report information through a communication
device that sends the information, e.g., over wire-line or wireless
telephony to a network operations center. The network operation
center includes resident software which is programmed to interpret
that information. Then, the software firstly determines whether the
dairy farm operator needs to receive an alert or informational
message via telephone or any other electronic communications device
suggesting that the operator take appropriate action. Secondly, if
necessary, the software then presents the alert and sensor
information on a customized secure web site that the operator can
access to review the information and prepare the compliance
reporting for, e.g., HACCP-type activities.
Inventors: |
Stevens, Hilco; (Drayton,
CA) ; Stevens, John A.; (Drayton, CA) ;
Bosman, Jack B.; (Conestogo, CA) ; Wood, Larry
J.; (Drayton, CA) |
Correspondence
Address: |
BORDEN LADNER GERVAIS LLP
WORLD EXCHANGE PLAZA
100 QUEEN STREET SUITE 1100
OTTAWA
ON
K1P 1J9
CA
|
Family ID: |
27663060 |
Appl. No.: |
10/352948 |
Filed: |
January 29, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60352211 |
Jan 29, 2002 |
|
|
|
Current U.S.
Class: |
340/531 ;
340/521; 340/540; 340/573.3; 340/679 |
Current CPC
Class: |
A01J 5/007 20130101 |
Class at
Publication: |
340/531 ;
340/521; 340/540; 340/573.3; 340/679 |
International
Class: |
G08B 001/00 |
Claims
We claim:
1. A system comprising sensors, which are selected from the group
consisting of, analog and digital sensors, that are installed on
equipment on a dairy farm that will report information through a
communication device that sends the information over wire-line or
wireless telephony to a network operations center that includes
software, wherein: in that said software is programmed to interpret
that information, and then: firstly to determine whether the dairy
farm operator needs to receive an alert or informational message
via telephone or any other electronic communications device
suggesting that the operator take appropriate action; and secondly,
to present the alert and sensor information on a customized secure
web site that the operator can access to review the information and
prepare the compliance reporting for HACCP-type activities.
2. The system as claimed in claim 1, wherein said system is
configured to be able to add additional sensors, which are selected
from the group consisting, of analog and digital sensors, of
various types at various locations at the dairy farm operation and
report information from those sensors on an alerting and
informational basis and present that information on a customized
secure web site that the operator can access to review the
information and prepare the compliance reporting for HACCP-type or
other activities.
3. The system as claimed in claim 1, wherein said system is
configured to have the alarming and reporting conditions of the
system set by the operator through a customized secure web
site.
4. The system as claimed in claim 1, wherein said system is
configured to instruct various mechanical devices on the dairy farm
to perform various functions based on information which is received
and interpreted by the software of the network operations
center.
5. The system according to claim 1, wherein said system is
configured to enable multiple users to review the information which
is collected an any number of dairy farms in any number of location
through the network operations center
6. The system according to claim 1, wherein said software is
encoded with a set of business rules, whereby: said software can
continually monitor any number of conditions on any number of dairy
farms in any number of locations against a set of site-specific and
regulatory thresholds of raw milk quality standards.
7. A milk storage and quality control system comprising: a) a milk
flow line from a milking station to a milk storage tank; b) a
volume sensor for determining the volume of milk; c) a temperature
sensor in said milk flow line; d) a milk storage tank temperature
sensor; and e) an alarm for alerting when the temperature of milk
in said milk storage tank is outside of upper and lower threshold
temperature limits, said alarm providing an indication of the
quality of milk stored in said storage tank so that appropriate
corrective or other action may manually or automatically be taken
with respect to said milk in said milk storage tank.
8. The milk storage and quality control system as claimed in claim
7, further including f) a refrigeration line to cool said milk
storage tank; g) a refrigerant line temperature sensor; and h) an
alarm, said alarm providing an indication that the temperature in
said refrigerant line is higher than a predetermined maximum
temperature or lower than a predetermined minimum temperature so
that appropriate corrective or other action may manually or
automatically be taken with respect to said milk in said milk
storage tank.
9. The milk storage and quality control system as claimed in claim
7, further including i) a wash or cleaning solution pump including
a wash or cleaning solution control; j) valve means to disrupt the
flow of milk into said milk storage tank prior to allowing entry of
wash or cleaning solution into said milk storage tank; and a
temperature sensor to provide an alarm to indicate that the
temperature of the wash or cleaning solution is outside preselected
minimum and maximum washing or cleaning temperatures, said
temperature sensor providing an indication of inadequate cleaning
of said milk cleaning tank so that appropriate corrective or other
action may manually or automatically be taken with respect to said
wash or cleaning solution.
10. A method of monitoring the storage of milk in a milk storage
tank comprising the steps of: continuously monitoring the
temperature of milk in said milk storage tank; providing an alarm
when the temperature of milk in said milk storage tank is less than
a preselected minimum or more than a preselected maximum threshold
temperatures; and manually or automatically taking appropriate
corrective or other action with respect to milk in said milk
storage tank in response to said alarm.
11. The method as claimed in claim 10, which includes the steps of:
continuously monitoring the temperature of refrigerant which cools
milk in said milk storage tank; providing an alarm when the
temperature of the refrigerant is less than a preselected minimum
cooling temperature or more than a preselected maximum cooling
temperature; and manually or automatically taking appropriate
corrective or other action.
12. The method as claimed in claim 10, which further includes the
steps of: continuously monitoring the temperature of milk entering
the milk storage tank; providing an alarm when the temperature of
the milk is outside predetermined minimum and maximum threshold
values; and manually or automatically taking appropriate corrective
or other action.
13. The method as claimed in claim 10, which still further includes
the steps of: monitoring the temperature of a hot wash or cleaning
solution in said milk storage tank; providing an alarm when the
temperature of the hot cleaning solution is less than a
predetermined minimum and more than a predetermined maximum
temperature, said alarm providing an indication of the
effectiveness of the cleaning of the milk storage tank; and
manually or automatically taking appropriate corrective or other
action.
14. A system for monitoring at least one parameter of a milk
storage facility, and for automatically providing an alarm that
said monitored parameter is outside of predefined thresholds,
comprising: (a) at least one sensor to monitor at least one said
parameter, and to generate signals which provide data which is
representative of said monitored parameter; (b) an "on-site"
communication device for receiving said data, for comparing said
data with said predefined thresholds, for providing an alarm when
said data is outside said thresholds, and to transmit said signals
to a network operation center; and (c) wherein said network
operation center is configured for receiving said signals from said
"on-site" communication device, said network operations center
having resident software which is programmed to process data which
is received from said "on-site" communications device, and to
generate preselected information signals.
15. The system as claimed in claim 14, wherein said sensors include
at least one of a storage tank temperature sensor, a condensing
unit temperature sensor, a storage tank "clean-in-place" sensor, a
vacuum pump sensor, a fill pipe sensor, a storage tank agitation
sensor, a milk meter sensor and a harvesting equipment
"clean-in-place" sensor.
16. The system as claimed in claim 14, wherein said "on-site"
communication device comprises a combined sensor receiver, data
logger processor and two-way communicator, for providing signals to
at least one of an "on-site" alarm system and an "on-site"
display.
17. The system as claimed in claim 14, wherein said software which
is resident in said "off-site" network communication center is
programmed to generate at least one of information signals which is
selected from the group comprising: an alert signal to an "on-site"
telephone; an alert signal to an "on-site" alarming device; an
alert signal to any other "on-site" electronic communication
device; an alert signal to a processor at a regulatory agency; an
alert signal to a processor at a milk collection company; and a
signal to a recorder to print a hard copy of the data for analysis
and compliance reporting.
Description
[0001] This application claims benefit of priority from U.S.
Provisional Application No. 60/352,211, filed Jan. 29, 2002.
(1) BACKGROUND OF THE INVENTION
[0002] (a) Field of the Invention
[0003] The present invention generally relates to the monitoring of
the quality of the raw-milk which is produced and stored on dairy
farms, and includes both systems and methods which are concerned
herewith.
[0004] (b) Background Art
[0005] Raw milk from cows which is harvested with "milking"
equipment on dairy farms is generally transferred via a network of
piping, pumps, filters and possible heat exchangers into one or
more storage tanks which are located on the dairy farm. Such
harvesting sessions usually occur several times daily. The raw milk
which has been transferred into the storage tank should be cooled
to a predefined industry standard temperature for raw milk storage,
within an industry specified time frame, as specified by certain
regulatory bodies. Generally, raw milk is stored at temperatures no
higher than 38.degree. F. (3.degree. C.) to ensure that small
amounts of bacteria already existing in raw milk does not
proliferate and degrade the quality of milk prior to transport to a
processing plant.
[0006] The storage tanks on the dairy farm generally consist of a
double-walled, insulated, stainless steel vessel. Some storage
tanks may have an evaporator plate fixed to the outside of the
inner stainless steel wall of the storage tank, through which a
refrigerant is circulated as the means to remove the heat from the
raw milk which is stored in the tank. Milk storage tanks without
fixed cooling apparatus are also common, in which case the milk is
cooled to the storage temperature for raw milk prior to entry into
the storage tank.
[0007] The storage tank is charged with raw milk from one of any
number of daily milking sessions, depending on the size of the cow
herd and the number of times each cow is milked per day: At regular
intervals (typically but not limited to once every 2 days) the raw
milk is transferred to a milk transport truck for transport to a
processing plant. Once empty, the storage tank is washed, sanitized
and rinsed in preparation for subsequent storage of the next
milking sessions. Typically this "clean-in-place" (CIP) procedure
automatically circulates, first, a clear water rinse , followed by
detergent solution (usually alkaline) during which the cleaning
solution must maintain a temperature above a specified threshold
(determined by the blend of cleaning chemicals) for a specified
minimum period of time, generally a minimum of 110.degree. F.
(38.degree. C.) for no less than 4 to 9 minutes. Following the
detergent cleaning cycle, an acid solution is circulated. In some
cases, a final cold or tepid water rinse is used.
[0008] Occasionally operational errors of various kinds can occur
during the cleaning cycle. It is not uncommon for the detergent
cleaning solution to fall below the minimum temperature threshold
and thereby to compromise the cleaning process. In other cases,
various automatic mechanical cleaning equipment may malfunction,
thereby compromising the cleaning cycle in various ways. Human
error is also frequently a factor for failed cleaning
processes.
[0009] Some time after the "clean-in-place" procedure has been
completed (with or without mechanical or human failure), the dairy
farmer or herdsman (the "operator"), would normally commence the
next milk harvesting session during which raw milk will once again
be transferred from the collection equipment to the storage tank.
Typically, milk harvesting and cooling/storage equipment require
some degree of manual operation, varying with location. Typically,
operators are required to energize the milk harvesting and the
cooling equipment circuits. Timing of procedures varies both
within, and by location, and also by equipment configuration and
brands. Freshly harvested raw milk from this first session must now
be cooled within given allowable time periods. When the storage
tank/condensing unit circuit is energized, the milk begins to cool
to the required storage temperature. Typically, once the cooling
circuit is energized, a control thermostat will "call" for cooling,
causing the condensing unit to operate, thereby circulating liquid
refrigerant though heat exchangers. Refrigerant "boiling off" in
the heat exchangers will draw the heat from the warm milk. On some
farms, milk may be partially or fully cooled prior to transfer into
the storage tank, using various models of heat exchangers. After a
variable amount of time, a milk harvesting session will finish.
Typically, the cooling cycle will continue past the completion of
the milking session until the temperature inside the storage tank
is at the required level and the control thermostat automatically
de-energizes the condensing unit.
[0010] At any time after the first session and before the next
session, the control thermostat may call for cooling if the
temperature of the raw milk rises above the recommended storage
temperature. The control thermostat will continue to control the
cooling process until the storage tank is again emptied at which
time the cooling circuit will be energized.
[0011] At the start of a second milking session, the procedure
begins in the same manner as the above-described first milking
session. The operator starts the milk harvesting equipment. In many
cases, new warm raw milk from the second milking session is
collected for storage, and is diluted with the cooled milk from
previous session or sensors, creating a blended temperature. The
condensing unit circuit will be energized when the temperature
inside the storage tank rises above the control thermostat set
point. Sometime after the second milking session is over, blended
milk will be cooled to the storage temperature and the thermostat
will de-energize the condensing unit circuit.
[0012] Subsequent sessions will be completed until the stored raw
milk is collected for transport to the processing plant.
Immediately after the tank is emptied, a cleaning cycle is
completed, and the collection/storage/cleaning cycle will repeat
itself.
[0013] Throughout this procedure, any number of operator or
mechanical errors can occur. Any one of these errors or combination
of errors can cause less than optimal conditions for the storage of
raw milk. Less than ideal storage conditions of raw milk will
exponentially increase the level of bacterial growth in the stored
raw milk causing the quality of the raw milk to decrease and in
some cases to be rendered totally un-saleable. While in some cases
the sub-optimal raw milk may still be used in certain procedures
not requiring optimal quality raw milk, it is becoming the norm
that the entire quantity of raw milk which is held in the storage
tank be discarded as waste and the revenue to the dairy farmer is
thus permanently lost.
[0014] The quality of the raw milk in the storage tank will be
subjected to several qualitative tests prior to acceptance for
processing. The transport truck driver will visually inspect the
milk, smell the milk and in some cases taste it. If the transport
driver decides the milk is of poor quality, he may refuse to
collect the milk and the stored milk will be dumped. Oral
subjective testing is an inexact science and tends to put undue
pressure on the tester. After passing the oral test, a sample of
raw milk is collected for subsequent random laboratory testing for
conditions in the raw milk that cannot be detected by the oral
qualitative tests. A storage tank of raw milk may pass the
qualitative tests on the farm but later be found to have been of
poor quality. This will result in a warning being issued, possibly
a penalty levied, and depending on recent history, the producers
right to ship milk may be suspended until the cause of the
infraction is identified and corrected.
[0015] To aid in the monitoring and evaluating of stored milk there
are currently various makes and models of analog and digital data
loggers that can be attached to the storage tank to "log" the
ambient temperatures of the storage tank. Some models may also
record the temperatures of the milk harvesting cleaning cycles.
This information is used as proof of the actual temperatures of the
raw milk in the storage tank over the specified period of time
between milk pick ups. The operator and the milk transport truck
driver or other agent of the regulatory body can then review the
conditions of the raw milk in that specified period of time to
assist in the qualitative judging of the quality of the raw milk
stored in that particular storage tank. Conventional data loggers
and some model of storage tanks can also be equipped with audible
or visual alarms that will notify the operator of any conditions
that are detected to be outside a preset range of temperatures in
the storage tank.
[0016] Current alarm systems and data loggers, however useful, have
many shortfalls. Pre-occupied, un-responsible, or absent operators
are common. Data loggers are not routinely checked and faulty
storage conditions of the raw milk can go undetected until the
transport driver checks the data logger. Faulty storage conditions
occurring during the initial harvesting session when not promptly
detected, will contaminate subsequent fresh milk introduced for
storage. Many regions of the dairy industry are now considering
formalizing the data logging activity. In certain jurisdictions,
regulatory bodies are testing the reliability of data logging
equipment with a view to making it mandatory to have a data logger
on the storage tank to record both the temperature of the raw milk
in the storage tank between pick ups and the temperatures of the
cleaning cycles.
[0017] (c) Description of the Prior Art
[0018] Among the patent literature relating to the
above-referred-to apparatus and methods to monitor the quality of
milk are the following:
[0019] U.S. Pat. No. 4,455,483, patented Jun. 19, 1984, by M. J.
Schonhuber which was directed to a system for recording data
relating to specific lots of milk. The data were collected at
delivery locations by a collecting vehicle and were brought by the
vehicle to a collecting station. The system included a recorder in
the vehicle. The recorder included data input means, a controlled
unit means and memory means. The system further included a
collecting station where data from the vehicle was converted and
stored on two different data carriers. The system further included
stationary data processing units which received the data from the
two different data carrying units in the collecting stations.
[0020] U.S. Pat. No. 4,612,537, patented Sep. 16, 1986, by A.
Maltairs et al, which was directed to an alarm system for
monitoring the temperature of a liquid contained in a reservoir.
The system included a temperature sensing probe for sensing the
temperature of the liquid. A sensing circuit was associated with
the probe to generate a temperature-indicating signal which was
representative of the liquid temperature. A calibration circuit was
provided for calibrating the temperature signal relative to a
reference signal. Converter means was provided to convert the
calibrated temperature signal to a binary signal which was
indicative of sensed temperatures of the liquid. This fed
comparator circuits having pre-set limit detectors to initiate an
alarm signal when the temperature signal exceeded a predetermined
value. The comparator circuits also fed a display device to
indicate the temperature of the liquid.
[0021] U.S. Pat. No. 4,710,755, patented Dec. 1, 1987, by R. A.
Gurney, which was directed to an alarm for a milk cooler, which
sounded an alarm when the temperature of milk within the cooler
exceeded a predetermined value. A switch permitted the device to be
turned off to prevent it from sounding such alarm when milk was
being discharged from the cooler, or when the cooler was being
cleaned with hot cleaning solvent. However, when fresh milk was
being introduced into the cooler, that switch was overridden and
the alarm sounded should the milk not be cooled to the required
temperature after a predetermined interval of time.
[0022] U.S. Pat. No. 5,743,209, patented Apr. 28, 1998, by S. Bazin
et al, which was directed to a system and method for monitoring and
controlling milk production at dairy farms. That patent provided an
automated modular system, whose operation provided a method for
officially controlling the quantity and quality of milk production
at a dairy farm site. The method included the first steps of
assigning each dairy herd an identification code and also assigning
each milk producing animal in each herd a unique animal
identification code. The quantitative milk production from an
individual animal was measured using a milk flow meter which was
temporarily connectable with a milking machine for an individual
animal. The milk flow meter was capable of continuously weighing
milk produced per unit time by an individual animal during a single
milking session. A qualitative analysis of the composition of a
sample of milk from an individual dairy animal was provided. Such
analysis included an infra-red optical probe. A system control and
memory was connected to the milk flow meter and to the qualitative
analysis. A dairy herd code was entered into the system control and
thereby initiated control of the herd and accessing stored data for
herd and each individual dairy animal therein. An individual dairy
animal identification code was entered in the system control when
the corresponding individual dairy animal was present at the
milking machine, thereby activating the milk flow meter.
Quantitative milk production from the individual dairy animal was
measured. A sample of milk from the individual dairy animal was
quantitatively analyzed. Completion of milking session as indicated
by milk flow meter was detected, and memory data from the milking
session was stored in the system.
[0023] U.S. Pat. No. 5,996,529, patented Dec. 7, 1999, by K. L.
Sisson et al, which was directed to a milk metering and cow I.D.
system, for use in a milking parlor having a plurality of stalls.
The system monitored milk production and identified each of a
plurality of animals being milked. A plurality of milk metering
subsystems was included, each of which was assigned to one of a
plurality of stalls. The milk metering subsystem sensed the
temperature of milk and/or wash flowing through the milk metering
subsystem. A host computer managed both the flow of data throughout
the system and the operation of the milk metering subsystems by way
of a remotely-located system interface between the computer and
each of the milk metering subsystems. An RS-485 connection between
each of the plurality of milk metering subsystems and system
interface was included. The system also included at least one
antenna which received animal identification data for each of the
animals being milked and electrically communicated that
identification data the host computer. A plurality of transponders
was included in which one was located on an ear of each monitored
animals. A receiver was also provided for each stall. Milk
production data was automatically transferred to the host computer
after the expiration of a time period following a triggering even,
at the end of a shift, or on demand.
[0024] U.S. Pat. No. 6,006,615, patented Dec. 28, 1999, by M. J.
Uttinger, which was directed to a remote data acquisition system,
which included a sensor into a storage device. The sensor was
capable of sensing at least one parameter, e.g., the temperature of
the material stored in the storage device. The remote data
acquisition system also included transmission means associated with
the sensor and which was capable of outputting the information
sensed by the sensor, or a data storage device to store the
information sensed. That patent also provided a method of
allocating the type of processing accorded to material collected
from a storage device. In carrying out such method, the storage
device incorporated at least one sensor which was capable of
reading parameters, e.g., temperatures of material held within the
storage device. The method included the steps of outputting the
information sensed from the sensor to a central processing station,
and using the output information to coordinate the type of
processing accorded in the material within the storage device.
[0025] According to that patentee, while the primary parameter
sensed by the sensor was temperature, other parameters, e.g., the
acidity of the milk, its density, conductivity, turbidity or
perhaps fat content, may be sensed instead of, or in addition to
temperature. According to that patentee, one could monitor the
electrical network. This was alleged to highlight any inadequate
power supplies. Monitoring of voltage/current demands on the dairy
hot water system used for cleaning purposes was alleged to provide
proof of water temperature. However, because of inherent faults,
this monitoring only provides a rough indirect estimate of the
temperatures throughout the system.
[0026] That patentee alleged that measuring the voltage/current
demands to the farm dairy pumping system responsible for movement
of milk from producing dairy cow through to the milk vat would
provide a measure of the milk flow. However, because of inherent
faults, this measuring only provided a rough indirect estimate of
the milk flow.
[0027] That patentee also suggested monitoring the clean-in-place
(CIP) equipment along with its efficiencies. For example, it was
suggested by that patentee that water temperature and volumes could
be monitored to ensure food hygiene standards were met with the
automated CIP system, or with alternative methods used for cleaning
milking machinery. However, there was no teaching of any alarm
system to report failure of the CIP procedure.
[0028] That patentee also suggested that the temperature of the
water supplied or used in relation to the refrigeration system be
monitored. The patentee thus suggested taking temperature readings
of water both entering and exiting the chiller system. However,
there was no teaching of any alarm to warn of any inadequacy of the
cooling system should the measured temperature of the water be
outside the predetermined upper and lower temperatures.
[0029] Thus, the above prior art leaves many other problems to be
addressed.
[0030] As a further development, the dairy industry is studying the
use of Hazard and Critical Control Points standards ("HACCP") which
are geared to a dairy farm operation and environment. HACCP
standards are currently in use at processing plants. Such standards
involve the documentation of compliance with raw milk handling,
cleaning/sanitation routines [i.e., clean-in-place] and other dairy
farm management standards.
(2) SUMMARY OF THE INVENTION
[0031] (a) Aims of the Invention
[0032] Accordingly there is a need for a system that can do more
than merely monitor and record cooling and cleaning conditions in
the storage tank. Such a system should also be able to detect
operator and mechanical errors that can effect the quality of raw
milk before the raw milk goes below optimal raw milk quality
standards. That system should be able to document the conditions of
the raw milk between milk truck pickups for purposes of HACCP-type
documentation, to be able to notify the operator through any
electronic means available of conditions that are outside the
quality thresholds whether the operator is physically at the
facility or not, and to be intelligent enough to determine the
stage of milk storage and harvesting sessions to apply the correct
thresholds of acceptable quality and be able to perform these
functions from information from an unlimited number of dairy farms
in independent locations at the same time. The system should be
tamper proof and be able to work dependably in less than ideal
installation conditions.
[0033] It is a first object of the present invention to address the
foregoing problems or at least to provide the public with a useful
choice.
[0034] It is a second object of the present invention to provide a
system that will alleviate at least in part the drawbacks of the
prior art.
[0035] It is a third object of the present invention to provide a
system that can be installed on the process equipment, including
but not limited to the vacuum pump, the milk pump, the condensing
unit, the storage tank and the interconnecting [hot gas return]
piping that can provide information about the temperature of the
raw milk prior to transfer into storage, temperature in the storage
tank, performance and operations of cooling systems, event time
stamping, and clean-in-place sessions.
[0036] It is a fourth object of the present invention to provide a
system whereby this information is transmitted by wire-line or
wireless telephony structure so that a central processing location
employing software which is tailored for the analyses of data
regarding the conditions on a particular farm and determine the
appropriate course of action to alert the appropriate producer
through telephony or any other electronic means.
[0037] It is a fifth object of the present invention to provide a
system whereby the information is made available and delivered on a
need-to-know basis to regulatory agencies for the purpose of
offsite monitoring of milk production facilities.
[0038] It is a sixth object of the present invention to provide a
system whereby the operator can set certain desired thresholds for
which pre-emptive alerts will be sent.
[0039] It is a seventh object of the present invention to provide a
system that will be able to provide information through sensors and
the communicating device of other conditions on the dairy farm that
may be required from time to time by the operator.
[0040] It is an eighth object of the present invention to provide a
system that will be able to control mechanical processes on the
dairy farm by way of additional devices that are instructed by the
software of the network operations center to perform a certain
function.
[0041] (b) Statement of the Invention
[0042] The present invention provides for an easy-to-install system
of sensors and communication devices that will allow operators to
detect operating problems before they happen and to present this
information in a HACCP-compliant way at a competitive cost.
[0043] One embodiment of this invention provides a system
comprising sensors, e.g., analog and/or digital sensors, that are
installed on equipment on a dairy farm that will report information
through a communication device that sends the information over
wire-line or wireless telephony to a network operations center that
includes software. The software is programmed to interpret that
information and then, firstly, to determine whether the dairy farm
operator needs to receive an alert or informational message via
telephone or any other electronic communications device suggesting
that the operator take appropriate action, and secondly, to present
alert and sensor information on a customized secure web site that
the operator can access to review the information and prepare the
compliance reporting for HACCP-type activities.
[0044] A second embodiment of this invention provides a milk
storage and quality control system. That system includes a milk
flow line from a milking station to a milk storage tank. A sensor
is provided determining the flow of milk in the milk line. A
temperature sensor is provided in the milk flow line. A temperature
sensor is also provided in a milk storage tank. An alarm is
provided to warn when the temperature of milk in the milk storage
tank is outside of upper and lower temperature limits. Means are
provided to withdraw milk from the milk storage tank. In this
system, the alarm provides an indication of the quality of milk
which is stored in the storage tank so that appropriate corrective
or other action may manually or automatically be taken with respect
to the milk in the milk storage tank.
[0045] A third embodiment of this invention provides a first method
of monitoring the storage of milk in a milk storage tank. The
method includes a first step of continuously monitoring the
temperature of milk in the milk storage tank. The next step
involves providing an alarm when the temperature of milk in the
milk storage tank is less than a preselected minimum temperature or
more than a preselected maximum temperature. The final step
involves manually or automatically taking appropriate corrective or
other action with respect to milk in the milk storage tank in
response to the alarm.
[0046] A fourth embodiment of this invention provides a system for
monitoring at least one parameter of a milk storage facility where
milk is stored "on-site" in a dairy facility, and for automatically
providing an alarm that such monitored parameter is outside of
predefined thresholds. The system includes at least one sensor to
monitor at least one parameter, and to generate signals which
provide data which is representative of the monitored parameter.
That system includes an "on-site" communication device for
receiving the data, for comparing the data with the predefined
thresholds, for providing an alarm when the data is outside the
thresholds. The system also includes an "off-site" network
communications center for receiving the signals from the secure web
site, the network operations center having resident software which
is programmed to process data which is received from the "on-site"
communications device, and to generate preselected information
signals.
[0047] (c) Other Features of the Invention
[0048] By a first feature of the first embodiment of this
invention, the system is configured to add additional sensors,
e.g., analog and/or digital sensors of various types at various
locations at the dairy farm operation, to report information from
those sensors on an alerting and informational basis, and to
present that information on a customized secure web site that the
operator can access to review the information and then to prepare
the compliance reporting for HACCP-type or other activities.
[0049] By a second feature of the first embodiment of this
invention, and/or the above feature, the system is configured to
have the alarming and reporting conditions of the system set by the
operator through a customized secure web site.
[0050] By a third feature of the first embodiment of this
invention, and/or the above features thereof, the system is
configured to instruct various mechanical devices on the dairy farm
to perform various functions based on information which is received
and interpreted by the software of the network operations
center.
[0051] By a fourth feature of the first embodiment of this
invention, and/or the above features thereof, the system is
configured to enable multiple users to review the information which
is collected on any number of dairy farms in any number of location
through the network operations center
[0052] By a fifth feature of the first embodiment of this
invention, and/or the above features thereof, the software is
encoded with a net of business rules whereby that software can
continually monitor any number of conditions on any number of dairy
farms in any number of locations against a set of site-specific and
regulatory thresholds of raw milk quality standards.
[0053] By a first feature of the second embodiment of this
invention, the milk storage and quality control system includes a
refrigeration line to cool the milk storage tank, the refrigeration
line including a refrigeration line temperature sensor, an alarm,
so that the alarm provides an indication that the temperature in
the refrigerant line is higher than a predetermined maximum
temperature or lower than a predetermined minimum temperature so
that appropriate corrective or other action may manually or
automatically be taken with respect to the milk in the milk storage
tank.
[0054] By a second feature of the second embodiment of this
invention, and/or the above features thereof, the milk storage and
quality control system also includes a wash pump including a wash
control, as well as a valve to disrupt the flow of milk into the
milk storage tank prior to allowing entry of wash solution into the
milk storage tank, and an alarm to indicate that the temperature of
the wash or cleaning solution is outside preselected washing
minimum and maximum temperatures, whereby the temperature sensor
provides an indication of inadequate cleaning of the milk cleaning
tank so that appropriate corrective or other action may manually or
automatically be taken with respect to the temperature of the wash
or cleaning solution.
[0055] By a first feature of the third embodiment of this
invention, the method includes the steps of continuously monitoring
the temperature of refrigerant for the cooling of milk in the milk
storage tank, providing an alarm when the temperature of the
refrigerant is less than a preselected minimum cooling temperature
or more than a preselected maximum cooling temperature, and
manually or automatically taking appropriate corrective or other
action.
[0056] By a second feature of the third embodiment of this
invention, and/or the above feature thereof, the method includes
the steps of continuously monitoring the volume of milk entering
the milk storage tank, providing an alarm when the volume of milk
is less than a predetermined minimum threshold value or more than a
predetermined maximum threshold value, and manually or
automatically taking appropriate corrective or other action.
[0057] By a third feature of the third embodiment of this
invention, and/or the above features thereof, the method includes
the steps of continuously monitoring the temperature of milk in the
milk storage tank, providing an alarm when the temperature of the
milk is outside predetermined minimum and maximum threshold values,
and manually or automatically taking appropriate corrective or
other action.
[0058] By a fourth feature of the third embodiment of this
invention, and/or the above features thereof, the method monitoring
the temperature of the hot wash or cleaning solution in the milk
storage tank, providing an alarm when the temperature of the hot
wash or cleaning solution is less than a predetermined minimum, or
more than a predetermined maximum temperature, whereby the alarm
provides an indication of the effectiveness of the cleaning of the
milk storage tank, and manually or automatically taking appropriate
corrective or other action.
[0059] By a first feature of the fourth embodiment of this
invention, the sensors include at least one of a storage tank
temperature sensor, a condensing unit temperature sensor, a storage
tank "clean-in-place" sensor, a vacuum pump sensor, a fill pipe
sensor, a storage tank agitation sensor, a milk meter sensor and a
harvesting equipment "clean-in-place" sensor.
[0060] By a second feature of the fourth embodiment of this
invention, and/or the above feature, the "on-site" communication
device comprises a combined sensor receiver, data logger processor
and two-way communicator, for providing signals to at least one of
an "on-site" alarm system and an "on-site" display.
[0061] By a third feature of the fourth embodiment of this
invention, and/or the above features, the software in the
"off-site" network communication center is programmed to generate
at least one of the following information signals: an alert signal
to an "on-site" telephone; an alert signal to an "on-site" alarming
device; an alert signal to any other "on-site" electronic
communication device; an alert signal to a processor at a
regulatory agency; an alert signal to a processor at a milk
collection company; and a signal to a recorder to print a hard copy
of the data for analysis and compliance reporting.
[0062] (d) Generalized Description of the Invention
[0063] As described above, by various embodiments of the present
invention, a system for monitoring of dairy farm process conditions
is disclosed. The system monitors the physical characteristics of
various operations on a dairy farm through the use of analog or
digital sensors which are strategically located on, or in, piping,
storage vessels, and livestock confinement areas. The sensors are
connected to an intelligent communication device that in turn
relays the information via wire-line or wireless telephony to an
"off-site" network operations center that can process the
information from an unlimited number of farms in any location. This
network operations center includes software for analyzing the
information in order to send out alarms for Hazard and Critical
Control Points standards ("HACCP"). Data from each location is
archived for further review or proof of process control for
regulatory purposes available to the customer and regulatory bodies
(on a need to know basis) through a secure, customer-specific
internet website.
[0064] On the dairy farm, (i.e., "on-site" analog or digital
sensors are attached to various parts of the equipment used to
harvest and store the raw milk including the vacuum pump, the milk
pump, the condensing unit, the milk storage tank(s) and the gas
lines of the condensing unit. Data reported by each sensor at each
of the locations, will initially be processed by an on-site
communications device and then by software residing at the network
operations center. Processed results will be compared against
industry wide and customizable thresholds set for each specific
location. Out-of-threshold conditions will generate instant or
delayed alerts (based on the urgency and risk of the condition and
the thresholds the farmer entered by way of the web site connection
to the software of the networks operations center). Alerts may be
delivered to farmer-specified telephone numbers, on site alarming
devices or any other means of electronic communication. Regardless
of the alerts, the information from the sensors is recorded and is
made available on a site-specific secure website for purposes of
analysis and compliance reporting. The web-site will also present
current news and information, information from any other customized
sensing information on the farm as well as the opportunity to order
supplies or services over the internet for later delivery.
(3) BRIEF DESCRIPTION OF THE FIGURES
[0065] In the accompanying drawings,
[0066] FIG. 1 is a flow chart of a system for the pre-emptive
monitoring of dairy production facilities.
[0067] FIG. 2 is a schematic representation of one embodiment of a
milk production, storage and milk delivery system.
(4) DESCRIPTION OF PREFERRED EMBODIMENTS
[0068] (a) Description of FIG. 1
[0069] FIG. 1 depicts the discrete components of one system of an
embodiment of this invention and the data flow path of
information.
[0070] Reference numbers 1 through 9 depict possible sensors which
are strategically placed on/in equipment on the farm. The data
generated by these sensors is used to monitor the procedures on the
farm and are provided "on-site". Thus, reference No. 1 represents
the storage tank temperature sensor; reference No. 2 represents the
condensing unit temperature sensor; reference No. 3 represents the
storage tank clean-in-place sensor; reference No. 4 represents the
vacuum pump sensor; reference No. 5 represents the fill pipe
sensor; reference No. 6 represents the storage tank agitation
sensor; reference No. 7 represents the milk meter sensor; reference
No. 8 represents the harvesting equipment clean-in-place sensor;
and reference No. 9 represents one or more future sensors.
[0071] The data from sensors reference Nos. 1 to 9 are fed to a
combined sensor receiver, data logger and two-way communication,
(10), which is an electronic device hereafter referred to as the
"Communicator".
[0072] The communicator (10) provides a two-way communication with
an "on-site" switching network (12). The communicator (10)
communicates one-way with an "on-site" alarm system (13) and also
with an "on-site" display (14), with output connections to any
number of display devices. Such display devices include personal
computers, CE computing devices, Palm.TM. platform devices, and
printers.
[0073] Also "on-site" are a telephone cell phone pager (11) and an
"on-site" personal computer (20).
[0074] Local internal service provider (hereinafter ISP) or local
wireless internet (15) which provides two-way communication with an
internet backbone (16) used for the economical instantaneous
delivery and distribution of data are provided "off-site". Local
ISP (15) provides the "on ramp" onto the internet backbone (16).
Local ISP (15) is the device by which out-of-condition alerts can
be received, typically by way of a wire-line or cell phone, pager
or wireless PIM which is capable of receiving text messaging.
Alarms are acknowledged using a customer specific code. The time of
acknowledgment is logged and stored as historical data. In
addition, local paging service (18) provides two-way communication
with local emergency service company (19).
[0075] Internet backbone (16) provides two-way communication with a
regulatory agency processor (23), a processor (22) and other
need-to-know systems (21). Processor (22) provides one-way
communication to the milk collection transportation company (24) as
well as to the regulatory agency processor (23)..
[0076] Finally, but importantly, the internet backbone (16) is in
two-way communication with the network operation center
[hereinafter NOC] (17).
[0077] The communicator (10) has capabilities which include: a)
gathering information from the sensors; b) transmitting data to the
NOC (17); c) receiving and applying logic (received from the NOC
(17)) to combinations of data received from the sensors for the
purpose of aiding in the detection of imminent emergency
situations; d) receiving and routing data to "on-site" switching
networks (12); and e) controlling "on-site" alarming devices
(13).
[0078] The NOC (17) is the control of the network. Data from the
communicator (10) is processed by customized software residing in
the NOC (17). "On-site" conditions found outside preprogrammed
thresholds would generate responses relative to the type of
out-of-condition situation. Alerts would be directed via a local
paging service (18) to the customer to inform him of the type and
severity of the out-of-condition situation. Alerts could also be
directed to emergency service companies (19) for the purpose of
prompt and efficient response to imminent out-of-condition
situations.
[0079] Data which is received is converted and may be presented in
a graphical manner for dissemination on a password-protected
website which is available to the customer.
[0080] Converted data may be subdivided for selective analysis on a
"need-to-know" basis to regulatory agencies, processors and other
companies having interest in the successful operation of the dairy
farm.
[0081] Data is archived for historical "proof of performance".
[0082] The on-site communicator (10) may also be provided with
residual individual or industry wide revised threshold conditions
and alarm logic.
[0083] The NOC (17) can monitor simultaneously any number of farms
world-wide, yet provide a personalized site per location. The NOC
(17) can also accommodate regionalised custom settings.
[0084] (b) Description of FIG. 2
[0085] FIG. 2 of the drawings shows a milk storage tank (210).
Within milk storage tank (210) is an agitator (211) for milk which
is stored in the milk storage tank (210). Agitator (211) is
provided with a sensor (212) to monitor the operation of the
agitator (211). Also within the milk storage tank (210) is a
storage tank temperature sensor (213).
[0086] Milk storage tank (210) is further provided with a milk
withdrawal line (214), leading to a milk tank (215).
[0087] Milk storage tank (210) is also-provided with an incoming
milk transfer line (216) which leads, via fill pipe (217), to the
milk storage tank (210). Milk transfer line (216) is provided with
a heat exchanger (218) to control the temperature of milk in the
milk transfer line (216), and with a milk transfer line
temperature/flow sensor (219).
[0088] Milk from a milking station (not seen) flows in a milk flow
line (220) to a transfer pump (221). The milk flow line (220) is
equipped with a milk meter volume sensor (222).
[0089] Transfer pump (221) is used to transfer raw milk from the
milk harvesting equipment to the milk storage tank (210).
[0090] Milk in the milk storage tank (210) is cooled by means of a
condensing unit (225). The high side gas line (226) of the
condenser unit (223) is provided with a refrigerant line
temperature sensor (224). The condensing unit (225) also includes a
low side gas line (228).
[0091] In order to clean the milk storage tank (210) after each
load has been discharged therefrom, a clean-in-place (hereinafter
CIP) system is provided. The CIP system includes a CIP vat (229)
which is provided with a harvesting equipment CIP sensor (230) and
is connected to the transfer pump (221) via wash or cleaning
solution line (231). A valve (232) is provided at the intersection
of lines (231) and (216). Valve (232) controls the unique flow of
wash or cleaning solution from line (231) to line (216), or the
unique flow of milk from line (220) to line (216).
[0092] This system also includes a wash or cleaning solution pump
(233) and a wash or cleaning solution control (234) connected
thereto by control line (238). The wash or cleaning solution pump
is equipped with a wash pump operation sensor (236)
[0093] (c) Operation of the System.
[0094] In operation, milk from the milk flow line is metered and
pumped into the milk storage tank after having passed through a
heat exchanger to reduce its temperature to an industry-standard
raw milk storage temperature.
[0095] The temperature of the milk in the milk storage tank after
every milking cycle is continuously monitored. If the temperature
is less than 36.degree. F., an alarm is triggered to warn of
freezing, and manually or automatically to institute corrective or
other action. In addition, the refrigerant line temperature sensor
alarm may be triggered to indicate that the excess cooling might be
due to a fault in the condensing unit, and manually or
automatically to institute corrective or other action. If the
temperature of milk in the milk storage tank exceeds 40.degree. F.
there is a possibility of spoilage of the milk or a degradation of
its quality for some future processing. The storage tank
temperature sensor is triggered so that appropriate corrective or
other action may manually or automatically be taken, either to
check the operation of the heat exchanger and/or the operation of
the condensing unit and/or the operation of the storage tank
agitator.
(5) CONCLUSION
[0096] As a consequence of the installation of the system of
embodiments of this invention, a complete management structure is
implemented with live data being accessed by users of the
system.
[0097] Total quality management is supported through the system.
The live data accessed can be referenced to the producing dairy
farm permitting the farmer and processing dairy factory to have
complete analysis on quality and quantity of milk produced together
the efficiencies of processing farm dairy equipment including milk
storage tanks, milk silos or other holding vessels and the
corresponding refrigeration/chiller systems. It also allows
operators to take corrective action before the quality of the raw
milk decreases.
[0098] Milk collection service completed by the dairy company milk
tankers and private contractors may be aided by the availability of
live data from the producing dairy farms.
[0099] From the foregoing description, one skilled in the art can
easily ascertain the essential characteristics of this invention,
and without departing from the spirit and scope thereof, can make
various changes and modifications of the invention to adapt it to
various usages and conditions. Consequently, such changes and
modifications are properly, equitably, and "intended" to be, within
the full range of equivalence of the following claims.
* * * * *